Abstract

This research aims to reduce the time required to change and install plastic injection molds for automotive parts and to increase the number of injected automotive parts produced at an automotive parts manufacturing plant. The current situation shows that the machine to be improved undergoes mold changes an average of 21 times per month, with a mold change and installation time of 66 minutes per instance. The researcher studied the mold change and installation procedures using work-study principles and direct time study methods and analyzed ways to improve by applying the Single Minute Exchange of Die (SMED) technique in conjunction with the ECRS (Eliminate, Combine, Rearrange, Simplify) and 5W1H (Who, What, Where, When, Why, How) principles. It was found that there was a mix of internal and external setup tasks. By separating internal and external tasks, it was discovered that 39.65% of the tasks were external, which could be performed while the machine was running. Utilizing ECRS This research aims to reduce the time required to change and install plastic injection molds for automotive parts and to increase the number of injected automotive parts produced at an automotive parts manufacturing plant. The current situation shows that the machine to be improved undergoes mold changes an average of 21 times per month, with a mold change and installation time of 66 minutes per instance. The researcher studied the mold change and installation procedures using work-study principles and direct time study methods and analyzed ways to improve by applying the Single Minute Exchange of Die (SMED) technique in conjunction with the ECRS (Eliminate, Combine, Rearrange, Simplify) and 5W1H (Who, What, Where, When, Why, How) principles. It was found that there was a mix of internal and external setup tasks. By separating internal and external tasks, it was discovered that 39.65% of the tasks were external, which could be performed while the machine was running. Utilizing ECRS principles, a separate color hot-runner system was installed to facilitate easier installation, and quick-connect couplings were added to reduce the time needed for hydraulic setup. After applying ECRS and 5W1H principles, the time for changing and installing plastic injection molds for automotive parts was reduced by 31%, and the number of injected automotive parts increased by 10%.